# US 9,518,711 B2 · Modular headlamp assembly > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,518,711 B2 - Document ID: US9518711B2 - Status: Granted - Kind: B2 - Application number: 13/246,481 - Filed: 2011-09-27 - Published: 2013-03-28 - Granted: 2016-12-13 - Earliest claimed: 2011-09-27 - Assignees: Truck-Lite Co., LLC - Applicants: Mike Marley; Gregory Alan Stoi - Inventors: Mike Marley; Gregory Alan Stoi - Web page: https://patentgrep.com/patent/US9518711B2 ## CPC - F21S 41/19: Attachment of light sources or lamp holders (achieving variable light distribution by movable light sources F21S41/657) - F21S 41/148: the main emission direction of the LED being perpendicular to the optical axis - F21S 41/336: {with discontinuity at the junction between adjacent areas} - F21S 41/39: Attachment thereof (achieving variable light distribution by movable reflectors F21S41/675) - F21S 41/43: characterised by the shape thereof - F21S 45/48: with means for conducting heat from the inside to the outside of the lighting devices, e.g. with fins on the outer surface of the lighting device - F21S 45/49: Attachment of the cooling means - F21S: NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS ## Abstract A modular headlamp assembly includes a low beam headlamp module, a high beam headlamp module, and front turn/parking lamp module. The low beam headlamp module and the high beam headlamp module are supported by a reflector carrier. Each of the high and low beam headlamp modules includes a heat sink and mounting assembly with a heat sink portion bisecting a reflector member. The reflector carrier is adjustably fastened to a housing to allow for adjustment of the high and low beam headlamp modules within the modular headlamp assembly. ## Claims ### Claim 1 A modular high and low beam headlamp assembly with a housing, said headlamp assembly comprising: a low beam headlamp module including: a low beam heat sink and mounting assembly having a low beam heat sink portion with first and second sides and a low beam mounting portion having alignment features formed therein; at least one first low beam LED light source supported by said first side of the low beam heat sink portion; at least one second low beam LED light source supported by said second side of the low beam heat sink portion; and a low beam reflector member attached to the low beam heat sink and mounting assembly such that the low beam heat sink portion separates the low beam reflector member into first and second segments such that light emitted by said at least one first low beam LED light source is reflected by the first segment and light emitted by said at least one second low beam LED light source is reflected by the second segment, said low beam reflector member including mating features for engaging the alignment features formed on the low beam mounting portion to facilitate the alignment of the low beam reflector member to the low beam heat sink and mounting assembly; a high beam headlamp module positioned adjacent to the low beam headlamp module including: at least one high beam LED light source; a high beam heat sink and mounting assembly including a high beam heat sink portion having first and second sides, said first side supporting the at least one high beam LED light source and a high beam mounting portion, said high beam mounting portion having alignment features formed therein; a thermally conductive compound disposed between the high beam heat sink and the at least one high beam LED light source; a high beam reflector member including an upper reflective portion and a lower portion, which are separated by the high beam heat sink portion, said high beam reflector member including mating features engaging the alignment features formed on the high beam mounting portion to facilitate the alignment of the high beam reflector member with the high beam heat sink and mounting assembly; and a reflector carrier including: a first receiving pocket containing the low beam headlamp module, the first receiving pocket having recesses formed therein accepting mounting extensions of the low beam headlamp module such that low beam headlamp module is aligned within reflector carrier; a second receiving pocket containing the high beam headlamp module, the second receiving pocket having recesses formed therein for accepting mounting extensions of the high beam headlamp module such that high beam headlamp module is aligned within said reflector carrier; and a plurality of attachment features formed within a back side of the reflector carrier, wherein at least one of said plurality of attachment features facilitates adjustable attachment of the reflector carrier to the housing. ### Claim 2 (depends on 1) The headlamp assembly of claim 1 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are formed from a thermally conductive material. ### Claim 3 (depends on 2) The headlamp assembly of claim 2 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are formed from a material in the group consisting of aluminum, copper and magnesium. ### Claim 4 (depends on 2) The headlamp assembly of claim 2 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are treated with a thermally emissive coating to facilitate heat transfer through radiation. ### Claim 5 (depends on 4) The headlamp assembly of claim 4 wherein the thermally emissive coating is an E-coat, an anodized coating, or a powder coat. ### Claim 6 (depends on 1) The headlamp assembly claim 1 wherein the low beam heat sink portion is oriented vertically such that it bisects the low beam headlamp module vertically. ### Claim 7 (depends on 1) The headlamp assembly of claim 1 wherein the low beam heat sink portion is oriented horizontally such that it bisects low beam headlamp module horizontally. ### Claim 8 (depends on 1) The headlamp assembly of claim 1 wherein the low beam mounting structure portion includes a plurality of mounting extensions protruding therefrom to facilitate alignment of the low beam headlamp module within the first receiving pocket of the reflector carrier and the high beam mounting structure portion includes a plurality of mounting extensions protruding therefrom to facilitate alignment of the high beam headlamp module within the second receiving pocket of the reflector carrier. ### Claim 9 (depends on 1) The headlamp assembly of claim 1 wherein the high beam reflector member and the low beam reflector member are formed of a thermoplastic or thermoset vacuum metalized material. ### Claim 10 (depends on 1) The headlamp assembly of claim 1 wherein the low beam heat sink portion includes a light source receiving portion formed therein on at least one of said first and second sides for receiving the at least one low beam LED light source and the high beam heat sink portion includes a light source receiving portion formed within the first side for receiving the at least one high beam LED light source. ### Claim 11 (depends on 1) The headlamp assembly of claim 1 wherein the high beam mounting portion includes fins for heat dissipation which terminate at a base portion of the high beam mounting portion. ### Claim 12 (depends on 10) The headlamp assembly of claim 10 wherein the light shield blocks light from the at least one low beam LED light source in a 10 U-90 U range. ### Claim 13 (depends on 1) The headlamp assembly of claim 1 further comprising a socket and a pivot stud attached to at least one of said plurality of attachment features and a socket and adjuster pivot stud attached to another one of said plurality of attachment features, wherein adjuster pivot stud is adapted to facilitate movement of the reflector carrier with respect to the housing. ### Claim 14 A modular high and low beam headlamp assembly comprising: a low beam headlamp module including: a low beam heat sink and mounting assembly having a low beam heat sink portion with first and second sides and a low beam mounting portion having alignment features formed therein; at least one first low beam LED light source supported by said first side of the low beam heat sink portion; at least one second low beam LED light source supported by said second side of the low beam heat sink portion; a light shield positioned adjacent to the at least one low beam LED light source for blocking a portion of the light in a low beam pattern; and a low beam reflector member attached to the low beam heat sink and mounting assembly such that the low beam heat sink portion separates the low beam reflector member into first and second segments such that light emitted by said at least one first low beam LED light source is reflected by the first segment and the light emitted by said least one second low beam LED light source is reflected by the second segment, said low beam reflector member including mating features for engaging the alignment features formed on the low beam mounting portion to facilitate the alignment of the low beam reflector member to the low beam heat sink and mounting assembly; a high beam headlamp module positioned adjacent to the low beam headlamp module including: at least one high beam LED light source; a high beam heat sink and mounting assembly including a high beam heat sink portion having first and second sides, said first side supporting the at least one high beam LED light source and a high beam mounting portion, said high beam mounting portion having alignment features formed therein; a high beam reflector member including an upper reflective portion and a lower portion, which are separated by the high beam heat sink portion, said high beam reflector member including mating features for engaging the alignment features formed on the high beam mounting portion to facilitate the alignment of the high beam reflector member with the high beam heat sink and mounting assembly; and a reflector carrier including: a first receiving pocket containing the low beam headlamp module, the first receiving pocket having recesses formed therein for accepting mounting extensions of the low beam headlamp module such that low beam headlamp module is aligned within said reflector carrier; a second receiving pocket containing the high beam headlamp module, the second receiving pocket having recesses formed therein for accepting mounting extensions of the high beam headlamp module such that high beam headlamp module is aligned within said reflector carrier; and a plurality of attachment features formed within a back side of the reflector carrier, wherein at least one of said plurality of attachment features facilitates adjustable attachment of the reflector carrier to a housing; and a housing including: an interior portion having a reflector carrier receiving portion defined therein, said reflector carrier receiving portion having attachment points through which at least one of the attachment features of the reflector carrier is adjustably fastened to the housing; a front turn/parking lamp reflector mounting area formed within the interior portion, said front turn/parking lamp reflector mounting area having attachment features through which the front turn/parking lamp reflector is attached to the housing; a cam feature formed within the front turn/parking lamp reflector mounting area for facilitating the attachment of a front turn/parking lamp socket assembly to the housing; an exterior portion having attachment points through which the housing is adapted to be mounted to a vehicle; and a circuit board module receiving opening formed within the interior portion of the housing for engaging a drive circuit housing. ### Claim 15 (depends on 14) The headlamp assembly of claim 14 further comprising a drive circuit module including a drive circuit housing with an interior portion adapted to contain a circuit board, a back portion having fins formed therein for heat dissipation and attachment tabs extending from drive circuit housing for attaching the drive circuit module to the headlamp housing at the circuit board module receiving opening. ### Claim 16 (depends on 14) The headlamp assembly of claim 14 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are formed from a thermally conductive material. ### Claim 17 (depends on 14) The headlamp assembly of claim 14 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are formed from a material in the group consisting of aluminum, copper and magnesium. ### Claim 18 (depends on 14) The headlamp assembly of claim 14 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are treated with a thermally emissive coating to facilitate heat transfer through radiation and wherein the thermally emissive coating is an E-coat, an anodized coating, or a powder coat. ### Claim 19 (depends on 14) The headlamp assembly claim 14 wherein the low beam heat sink portion is oriented vertically such that it bisects the low beam headlamp module vertically. ### Claim 20 (depends on 14) The headlamp assembly of claim 14 wherein the low beam heat sink portion is oriented horizontally such that it bisects low beam headlamp module horizontally. ### Claim 21 (depends on 14) The headlamp assembly of claim 14 wherein the low beam mounting structure portion includes a plurality of mounting extensions protruding therefrom to facilitate alignment of the low beam headlamp module within the first receiving pocket of the reflector carrier and the high beam mounting structure portion includes a plurality of mounting extensions protruding therefrom to facilitate alignment of the high beam headlamp module within the second receiving pocket of the reflector carrier. ### Claim 22 (depends on 14) The headlamp assembly of claim 14 wherein the high beam reflector member and the low beam reflector member are formed of a thermoplastic or thermoset vacuum metalized material. ### Claim 23 (depends on 14) The headlamp assembly of claim 14 wherein the low beam heat sink portion includes a light source receiving portion formed therein on at least one of said first and second sides for receiving the at least one low beam LED light source and the high beam heat sink portion includes a light source receiving portion formed within the first side for receiving the at least one high beam LED light source. ### Claim 24 (depends on 14) The headlamp assembly of claim 14 wherein the high beam mounting portion includes fins for heat dissipation which terminate at a base portion of the high beam mounting portion. ### Claim 25 (depends on 23) The headlamp assembly of claim 23 wherein the light shield blocks light from the at least one low beam LED light source in a 10 U-90 U range. ### Claim 26 (depends on 23) The headlamp assembly of claim 23 wherein the reflector carrier further includes a carrier stabilizer feature extending from the reflector carrier to facilitate attachment of reflector carrier to the housing. ### Claim 27 (depends on 23) The headlamp assembly of claim 23 wherein the reflector carrier further includes: a receiving slot for a side reflex reflector; a slit formed in the receiving slot for accommodating a snap feature formed on said side reflex reflector; and a notch formed on an inner wall of reflector carrier adjacent to the slit for mating with the snap feature to secure a position of side reflex reflector within receiving slot. ### Claim 28 (depends on 23) The headlamp assembly of claim 23 wherein the reflector carrier further includes a socket and a pivot stud attached to at least one of said plurality of attachment features and a socket and adjuster pivot stud attached to another one of said plurality of attachment features, wherein adjuster pivot stud is adapted to facilitate movement of the reflector carrier with respect to the housing. ### Claim 29 In a headlamp assembly with a housing including a high beam headlamp module with mounting extensions, a low beam headlamp module with mounting extensions, a reflector carrier comprising: a base; a first receiving pocket formed within the base containing the low beam headlamp module, the first receiving pocket having recesses formed therein for accepting mounting extensions of the low beam headlamp module such that low beam headlamp module fits within and is aligned within said reflector carrier; a second receiving pocket containing the high beam headlamp module, the second receiving pocket having a side wall extending forwardly from said base such that said second receiving pocket is positioned forwardly of said first receiving pocket, said second receiving pocket having recesses formed therein for accepting mounting extensions of the high beam headlamp module such that high beam headlamp module fits within and is aligned within said reflector carrier; wherein said high beam headlamp module is positioned adjacent to said low beam headlamp module; and a plurality of attachment features formed within a back side of the reflector carrier, wherein at least one of said plurality of attachment features facilitates adjustable attachment of the reflector carrier to the housing. ### Claim 30 (depends on 29) The reflector carrier of claim 29 further comprising a receiving slot for a side reflex reflector. ### Claim 31 (depends on 30) The reflector carrier of claim 30 wherein the reflector carrier further includes: a slit formed in the receiving slot for accommodating a snap feature formed on side reflex reflector and a notch formed on an inner wall of reflector carrier adjacent to the slit for mating with the snap feature to secure a position of side reflex reflector within receiving slot. ### Claim 32 (depends on 29) The reflector carrier of claim 29 further comprising a socket and a pivot stud attached to at least one of said plurality of attachment features and a socket and adjuster pivot stud attached to another one of said plurality of attachment features, wherein adjuster pivot stud is adapted to facilitate movement of the reflector carrier with respect to the housing. ### Claim 33 (depends on 29) The reflector carrier of claim 29 further comprising a carrier stabilizer feature extending from the reflector carrier to facilitate attachment of reflector carrier to the housing. ### Claim 34 A modular high and low beam headlamp assembly with a housing, said headlamp assembly comprising: a low beam headlamp module including: a low beam heat sink and mounting assembly having a low beam heat sink portion with first and second sides and a low beam mounting portion having alignment features formed therein; a low beam reflector member coupled to the low beam heat sink and mounting assembly such that the low beam heat sink portion separates the low beam reflector member in to first and second segments; a first low beam LED light source positioned on said first side of the low beam heat sink portion for direction light towards said first segment of the low beam reflector; a second low beam LED light source positioned on said second side of the low beam heat sink portion for direction light towards said first segment of the low beam reflector; a high beam headlamp module positioned adjacent to the low beam headlamp module including: a high beam heat sink and mounting assembly including a high beam heat sink portion having first and second sides; a high beam reflector member including an upper reflective portion and a lower portion, which are separated by the high beam heat sink portion; at least one high beam LED light source positioned on a first side of the high beam heat sink portion; and a reflector carrier including: a first receiving pocket containing the low beam headlamp module; a second receiving pocket containing the high beam headlamp module; and a plurality of attachment features formed within a back side of the reflector carrier, wherein at least one of said plurality of attachment features facilitates adjustable attachment of the reflector carrier to the housing, wherein said reflector carrier is contained within the housing. ### Claim 35 (depends on 34) The modular high and low beam headlamp assembly of claim 34 wherein the low beam heat sink is oriented in a first plane and the high beam heat sink is oriented in a second plane that is perpendicular to the first plane. ### Claim 36 (depends on 35) The modular high and low beam headlamp assembly of claim 35 wherein the first low beam LED light source has a first optical axis and the second low beam LED light source has a second optical axis and the at least one high beam LED light source has a third optical axis that is perpendicular to the first optical axis and second optical axis. ### Claim 37 (depends on 34) The modular high and low beam headlamp assembly of claim 34 wherein the low beam reflector includes an outer rim and said low beam heat sink portion includes an edge portion protruding beyond said outer rim.